U.S. patent application number 14/630679 was filed with the patent office on 2016-03-17 for method of manufacturing organic light-emitting display apparatus.
The applicant listed for this patent is SAMSUNG DISPLAY CO., LTD.. Invention is credited to Jinbaek CHOI, Jiyoung CHOUNG, Joongu LEE, Yeonhwa LEE.
Application Number | 20160079537 14/630679 |
Document ID | / |
Family ID | 55455649 |
Filed Date | 2016-03-17 |
United States Patent
Application |
20160079537 |
Kind Code |
A1 |
LEE; Joongu ; et
al. |
March 17, 2016 |
METHOD OF MANUFACTURING ORGANIC LIGHT-EMITTING DISPLAY
APPARATUS
Abstract
A method of manufacturing an organic light-emitting display
apparatus includes preparing a substrate with a plurality of pixel
electrodes, preparing a donor mask, such that the donor mask
includes a base substrate, a light-thermal conversion layer on the
base substrate, and a reflective layer between the base substrate
and the light-thermal conversion layer and having through-holes,
depositing a transfer layer on the light-thermal conversion layer
of the donor mask, aligning the substrate and the donor mask,
preheating at least a portion of the donor mask or the transfer
layer, and irradiating a light source toward the preheated portion
of the donor mask or the transfer layer, such that a portion of the
transfer layer is transferred from the donor mask to the pixel
electrodes of the substrate, the transferred portion of the
transfer layer corresponding to the through holes in the reflective
layer.
Inventors: |
LEE; Joongu; (Yongin-City,
KR) ; LEE; Yeonhwa; (Yongin-City, KR) ; CHOI;
Jinbaek; (Yongin-City, KR) ; CHOUNG; Jiyoung;
(Yongin-City, KR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SAMSUNG DISPLAY CO., LTD. |
Yongin-City |
|
KR |
|
|
Family ID: |
55455649 |
Appl. No.: |
14/630679 |
Filed: |
February 25, 2015 |
Current U.S.
Class: |
438/34 |
Current CPC
Class: |
H01L 27/3246 20130101;
H01L 51/0013 20130101; H01L 51/5012 20130101; H01L 27/3211
20130101; H01L 51/56 20130101 |
International
Class: |
H01L 51/00 20060101
H01L051/00; H01L 51/56 20060101 H01L051/56 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 15, 2014 |
KR |
10-2014-0122046 |
Claims
1. (canceled)
2. A method of manufacturing an organic light-emitting display
apparatus, the method comprising: preparing a substrate with a
plurality of pixel electrodes; preparing a donor mask, such that
the donor mask includes a base substrate, a light-thermal
conversion layer on the base substrate, and a reflective layer
between the base substrate and the light-thermal conversion layer
and having through-holes; depositing a transfer layer on the
light-thermal conversion layer of the donor mask; aligning the
substrate and the donor mask; preheating at least a portion of the
donor mask or the transfer layer; and irradiating a light source
toward the preheated portion of the donor mask or the transfer
layer, such that a portion of the transfer layer is transferred
from the donor mask to the plurality of pixel electrodes of the
substrate, the transferred portion of the transfer layer
corresponding to the through-holes in the reflective layer,
wherein: preheating includes irradiating a preliminary laser beam
toward at least a portion of the donor mask, such that a
corresponding portion of the transfer layer is preheated; and
irradiating includes irradiating a laser beam different from the
preliminary laser beam toward the preheated portions of the donor
mask and the transfer layer.
3. The method as claimed in claim 2, wherein the preliminary laser
beam is emitted by a preliminary laser beam source, and the laser
beam is emitted by a laser beam source different from the
preliminary laser beam source.
4. The method as claimed in claim 2, wherein the preliminary laser
beam and the laser beam are emitted by a single laser beam.
5. The method as claimed in claim 4, wherein the preliminary laser
beam and the laser beam are diverged from the single laser beam by
an optical element.
6. The method as claimed in claim 4, wherein the single laser beam
emits the preliminary laser beam and the laser beam with a time
difference therebetween.
7. The method as claimed in claim 2, wherein an intensity of the
preliminary laser beam is lower than an intensity of the laser
beam.
8. A method of manufacturing an organic light-emitting display
apparatus, the method comprising: preparing a substrate with a
plurality of pixel electrodes; preparing a donor mask, such that
the donor mask includes a base substrate, a light-thermal
conversion layer on the base substrate, and a reflective layer
between the base substrate and the light-thermal conversion layer
and having through-holes; depositing a transfer layer on the
light-thermal conversion layer of the donor mask; aligning the
substrate and the donor mask; preheating at least a portion of the
donor mask or the transfer layer; and irradiating a light source
toward the preheated portion of the donor mask or the transfer
layer, such that a portion of the transfer layer is transferred
from the donor mask to the plurality of pixel electrodes of the
substrate, the transferred portion of the transfer layer
corresponding to the through-holes in the reflective layer,
wherein: preheating includes irradiating a preliminary lamp light
toward at least a portion of the donor mask, such that a
corresponding portion of the transfer layer is preheated; and
irradiating includes irradiating a lamp light different from the
preliminary lamp light toward the preheated portions of the donor
mask and the transfer layer, wherein an intensity of the
preliminary lamp light is lower than an intensity of the lamp
light.
9. The method as claimed in claim 8, wherein the preliminary lamp
light is emitted by a preliminary lamp, and the lamp light is
emitted by a lamp different from the preliminary lamp light.
10. The method as claimed in claim 8, wherein the preliminary lamp
light and the lamp light are emitted by a single lamp light.
11. The method as claimed in claim 10, wherein the single lamp
light emits the preliminary lamp light and the lamp light with a
time difference therebetween.
12. (canceled)
13. The method as claimed in claim 5, wherein an intensity of the
preliminary laser beam is lower than an intensity of the laser
beam.
14. The method as claimed in claim 5, wherein the preliminary laser
beam and the laser beam are sequentially irradiated onto a same
predetermined area of the donor mask such that the laser beam
irradiates an area previously irradiated by the preliminary laser
beam.
15. The method as claimed in claim 10, wherein the preliminary lamp
light and the lamp light are sequentially irradiated onto a same
predetermined area of the donor mask such that the lamp light
irradiates an area previously irradiated by the preliminary lamp
light.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] Korean Patent Application No. 10-2014-0122046, filed on Sep.
15, 2014, in the Korean Intellectual Property Office, and entitled:
"Method of Manufacturing Organic Light-Emitting Display Apparatus,"
is incorporated by reference herein in its entirety.
BACKGROUND
[0002] 1. Field
[0003] One or more exemplary embodiments relate to a method of
manufacturing an organic light-emitting display apparatus, and more
particularly, to a method of manufacturing a high-quality organic
light-emitting display apparatus.
[0004] 2. Description of the Related Art
[0005] An organic light-emitting display apparatus is a display
apparatus having an organic light-emitting device in a display
area. The organic light-emitting device mainly includes a pixel
electrode, an opposite electrode facing the pixel electrode, and an
intermediate layer which is interposed between the pixel electrode
and the opposite electrode and includes an emission layer and other
layers. At least a portion of the layers included in the
intermediate layer are formed to correspond to each sub-pixel.
SUMMARY
[0006] One or more exemplary embodiments include a method of
manufacturing a high-quality organic light-emitting display
apparatus. However, the embodiments are only illustrative and are
not limited thereto.
[0007] According to one or more exemplary embodiments, a method of
manufacturing an organic light-emitting display apparatus includes
preparing a substrate with a plurality of pixel electrodes,
preparing a donor mask, such that the donor mask includes a base
substrate, a light-thermal conversion layer on the base substrate,
and a reflective layer between the base substrate and the
light-thermal conversion layer and having through-holes, depositing
a transfer layer on the light-thermal conversion layer of the donor
mask, aligning the substrate and the donor mask, preheating at
least a portion of the donor mask or the transfer layer, and
irradiating a light source toward the preheated portion of the
donor mask or the transfer layer, such that a portion of the
transfer layer is transferred from the donor mask to the pixel
electrodes of the substrate, the transferred portion of the
transfer layer corresponding to the through holes in the reflective
layer.
[0008] The transferring may include irradiating a preliminary laser
beam on at least a portion of the donor mask to preheat the donor
mask or the transfer layer and irradiating the laser beam on the
preheated portion of the donor mask or the transfer layer.
[0009] The preliminary laser beam may be emitted by a preliminary
laser beam source, and the laser beam may be emitted by a laser
beam source.
[0010] The preliminary laser beam and the laser beam may be emitted
by one laser beam source.
[0011] The preliminary laser beam and the laser beam may be
diverged from an original laser beam emitted by the one laser beam
source.
[0012] The one laser beam source may emit the preliminary laser
beam and the laser beam with a time difference therebetween.
[0013] The intensity of the preliminary laser beam may be weaker
than the intensity of the laser beam.
[0014] The transferring may include irradiating a preliminary lamp
light on at least a portion of the donor mask to preheat the donor
mask or the transfer layer and irradiating the lamp light on the
preheated portion of the donor mask or the transfer layer.
[0015] The preliminary lamp light may be emitted by a preliminary
lamp, and the lamp light may be emitted by a lamp.
[0016] The preliminary lamp light and the lamp light may be emitted
by one lamp.
[0017] The one lamp may emit the preliminary lamp light and the
lamp light with a time difference therebetween.
[0018] The intensity of the preliminary lamp light may be weaker
than the intensity of the lamp light.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Features will become apparent to those of ordinary skill in
the art by describing in detail exemplary embodiments with
reference to the attached drawings, in which:
[0020] FIGS. 1 to 4 illustrate cross-sectional diagrams of stages
in a method of manufacturing an organic light-emitting display
apparatus according to an exemplary embodiment according to an
exemplary embodiment;
[0021] FIG. 5 illustrates a side view of a manufacturing process in
a method of manufacturing an organic light-emitting display
apparatus according to an exemplary embodiment; and
[0022] FIG. 6 illustrates a side view of a manufacturing process in
a method of manufacturing an organic light-emitting display
apparatus according to another exemplary embodiment.
DETAILED DESCRIPTION
[0023] Example embodiments will now be described more fully
hereinafter with reference to the accompanying drawings; however,
they may be embodied in different forms and should not be construed
as limited to the embodiments set forth herein. Rather, these
embodiments are provided so that this disclosure will be thorough
and complete, and will fully convey exemplary implementations to
those skilled in the art.
[0024] In the drawing figures, the dimensions of layers and regions
may be exaggerated for clarity of illustration. It will also be
understood that when a layer or element is referred to as being
"on" another layer or substrate, it can be directly on the other
layer or substrate, or intervening layers may also be present. In
addition, it will also be understood that when a layer is referred
to as being "between" two layers, it can be the only layer between
the two layers, or one or more intervening layers may also be
present. Like reference numerals refer to like elements
throughout.
[0025] As used herein, the term "and/or" includes any and all
combinations of one or more of the associated listed items.
Further, in the following examples, the x-axis, the y-axis, and the
z-axis are not limited to three axes of the rectangular coordinate
system, and may be interpreted in a broader sense. For example, the
x-axis, the y-axis, and the z-axis may be perpendicular to one
another, or may represent different directions that are not
perpendicular to one another.
[0026] Referring to FIG. 1, a backplane is prepared. The backplane
may be a substrate 100 on which a plurality of pixel electrodes 210
are formed. As shown in FIG. 1, the backplane may also include a
pixel defining layer 180 formed so as to expose at least a portion
of a central part of each of the pixel electrodes 210. The pixel
defining layer 180 may protrude from the substrate 100 when
compared with the pixel electrodes 210.
[0027] The pixel electrode 210 may be a transparent (or
translucent) electrode or a reflective electrode. If the pixel
electrode 210 is a transparent (or translucent) electrode, the
pixel electrode 210 may be formed of, e.g., indium tin oxide (ITO),
indium zinc oxide (IZO), zinc oxide (ZnO), indium oxide
(In.sub.2O.sub.3), indium gallium oxide (IGO), or aluminum zinc
oxide (AZO). If the pixel electrode 210 is a reflective electrode,
the pixel electrode 210 may include a reflective layer formed of,
e.g., silver (Ag), magnesium (Mg), aluminum (Al), platinum (Pt),
palladium (Pd), gold (Au), nickel (Ni), neodymium (Nd), iridium
(Ir), chromium (Cr), a compound thereof, or the like, and a layer
formed of, e.g., ITO, IZO, ZnO, or In.sub.2O.sub.3. However, the
configuration and materials of the pixel electrode 210 are not
limited thereto, and various modifications may be performed.
[0028] The pixel defining layer 180 may define pixels with openings
corresponding to respective sub-pixels, i.e., openings for exposing
the central parts of the pixel electrodes 210 or entire surfaces of
the pixel electrodes 210. In addition, the pixel defining layer 180
may prevent the occurrence of an electric arc and the like at an
end portion of the pixel electrode 210 by increasing a distance
between the end portion of the pixel electrode 210 and an opposite
electrode (not shown) on an upper part of the pixel electrode
210.
[0029] The backplane may further include other various components
according to circumstances. For example, as shown in FIG. 1, a
thin-film transistor TFT and a capacitor Cap may be formed on the
substrate 100. In addition, the backplane may include a buffer
layer 110 formed on the substrate 100 to prevent permeation of
impurities into a semiconductor layer of the thin-film transistor
TFT. Further, the backplane may include a gate insulating layer 130
for insulating the semiconductor layer and a gate electrode of the
thin-film transistor TFT, an interlayer insulating layer 150 for
insulating source and drain electrodes and the gate electrode of
the thin-film transistor TFT, a planarization layer 170, which
covers the thin-film transistor TFT and of which an upper surface
is almost flat, and other components.
[0030] Next, referring to FIG. 2, after preparing the backplane, a
donor mask 300 is prepared and disposed so as to face the pixel
electrodes 210 and the pixel defining layer 180 of the backplane.
In detail, as shown in FIG. 2, the pixel electrodes 210 and the
pixel defining layer 180 of the backplane are oriented in a lower
direction (-z direction), and the donor mask 300 is disposed below
the backplane. Before the backplane and the donor mask 300 are
arranged, layers, e.g., a hole injection layer, a hole transport
layer, and the like, may be formed in advance on the pixel
electrodes 210 or on the entire surface of the substrate 100.
Although FIG. 2 illustrates that a considerable space exists
between the donor mask 300 and the backplane, this is only for
convenience of description, and the donor mask 300 and the
backplane may be closely attached to each other.
[0031] As further illustrated in FIG. 2, the donor mask 300 may
include a base substrate 310, a reflective layer 320, and a
light-thermal conversion layer 330. After preparing the donor mask
300, a transfer layer 340 is formed on the light-thermal conversion
layer 330 by deposition. According to embodiments, the transfer
layer 340 may be considered as one component of the donor mask 300.
In this case, the donor mask 300 includes the base substrate 310,
the reflective layer 320, the light-thermal conversion layer 330,
and the transfer layer 340.
[0032] The base substrate 310 forms the general outer appearance of
the donor mask 300, and may be formed of a transparent material,
e.g., glass, to allow light to reach the light-thermal conversion
layer 330. In another example, the base substrate 310 may be formed
of a polyester, e.g., polyethylene terephthalate (PET), polyacryl,
polyepoxy, polyethylene and/or polystyrene.
[0033] The light-thermal conversion layer 330 absorbs a flash lamp
light or a laser beam irradiated thereon and converts at least a
portion of the absorbed energy of the flash lamp light or the laser
beam into heat. The light-thermal conversion layer 330 may be a
layer made of metal, e.g., Al or Ag, an oxide/sulfide layer of the
metal, or a high-molecular organic layer including, e.g., carbon
black, graphite, or the like, which are capable of absorbing light
of an infrared-visible light band.
[0034] The reflective layer 320 is interposed between the base
substrate 310 and the light-thermal conversion layer 330. The
reflective layer 320 includes a plurality of through holes h, so
the base substrate 310 and the light-thermal conversion layer 330
may contact each other through the through holes h of the
reflective layer 320. Accordingly, the reflective layer 320 has
transmission areas TA corresponding to the through holes h and a
block area BA corresponding to the other portion. That is, the
through holes h in the reflective layer 320 define the transmission
areas TA that transmit light therethrough, e.g., transmit visible
light through the reflective area 320 and an entire thickness of
the mask 300, while areas of the reflective area 320 other than the
through holes h, i.e., areas of the reflective layer 320 including
reflective material, define the block areas BA that block light
transmittance therethrough.
[0035] The reflective layer 320 may be formed by forming the
plurality of through holes h by using a mask on the base substrate
310. For example, forming the reflective layer 320 may include
forming a layer having a uniform thickness, followed by removing a
portion of the formed layer via use of the mask to define the
plurality of through holes h in the formed layer. For example, the
reflective layer 320 may be formed of, e.g., titanium (Ti), Al,
copper (Cu), Ag, molybdenum (Mo), an alloy thereof, chromium
nitride (CrN), TiAlCu, or the like. In another example, the
reflective layer 320 may be formed of, e.g., titanium oxide
(TiO.sub.x), silicon oxide (SiO.sub.x), silicon carbon nitride
(SiCN), or the like.
[0036] The transfer layer 340 is a layer which may be evaporated,
vaporized, or sublimed by the heat generated by the light-thermal
conversion layer 330. That is, a portion of the transfer layer 340
that absorbs the heat generated by the light-thermal conversion
layer 330 is transferred to the backplane. For example, the
transfer layer 340 may be a layer including, e.g., an emission
material. In another example, the transfer layer 340 may also be a
layer including a hole injection material, a layer including a hole
transport material, a layer including an electron transport
material, or a layer including an electron injection material.
[0037] According to embodiments, the donor mask 300 may further
include an insulating layer (not shown) interposed between the
reflective layer 320 and the light-thermal conversion layer 330,
e.g., the insulating layer may include openings corresponding to
the through holes h of the reflective layer 320. The insulating
layer may prevent or reduce the delivery of heat generated by the
light-thermal conversion layer 330 to the reflective layer 320. If
heat generated in the light-thermal conversion layer 330 is
transferred to the reflective layer 320, it may then be delivered
to the block area BA along the reflective layer 320, rather than to
the transmission areas TA, thereby evaporating, vaporizing, or
subliming a portion of the transfer layer 340 in the block area BA
(which would cause incorrect formation of an emission layer on the
backplane).
[0038] As shown in FIG. 2, the backplane and the donor mask 300 are
aligned, so that the transmission areas TA of the reflective layer
320 of the donor mask 300 correspond to preset portions of the
backplane. That is, the through holes h of the reflective layer 320
of the donor mask 300 correspond to, e.g. overlap, respective pixel
electrodes 210. For example, the backplane and the donor mask 300
may be aligned, such that the through holes h of the reflective
layer 320 and the respective pixel electrodes 210 completely
overlap each other, e.g., a width of the through holes h in the x
direction may equal and completely overlap a width of the
corresponding exposed portions of the pixel electrode 210. For
example, as illustrated in FIG. 2, when the transfer layer 340 on
the donor mask 300 includes an emission material capable of
emitting a red light, the backplane and the donor mask 300 are
aligned so that the through holes h of the reflective layer 320 of
the donor mask 300 correspond to pixel electrodes 210 of red
sub-pixels R.
[0039] Thereafter, as shown in FIG. 3, a lamp light or a laser beam
is irradiated on, e.g., toward, the donor mask 300 by using a flash
lamp (not shown) or a laser beam oscillator (not shown). The lamp
light or a laser beam is positioned below the mask 300, i.e., such
that the mask 300 is between the light and the backplane, and the
light is irradiated through the mask 300 toward the backplane.
[0040] As illustrated in FIG. 4, as a result of the light
irradiation, a portion of the transfer layer 340 is transferred
from the donor mask 300 to the backplane, i.e., to the exposed
pixel electrode 210. In this case, even though the lamp light or
the laser beam is irradiated onto the entire surface of the donor
mask 300 by using the flash lamp or the laser beam oscillator, most
of the lamp light or the laser beam is blocked by the reflective
layer 320, and only a portion of the lamp light or the laser beam
reaches the light-thermal conversion layer 330 through the
transmission areas TA corresponding to the through holes h of the
reflective layer 320. Accordingly, only a portion of the transfer
layer 340 on the donor mask 300, which corresponds to the
transmission areas TA, is transferred to the backplane, i.e.,
evaporated, vaporized, or sublimed. As such, only the portion of
the transfer layer 340 irradiated with the light and transferred to
the pixel electrode 210 forms an emission layer, e.g., a red
emission layer 220R, on the pixel electrode 210, e.g., of red
sub-pixels R. Further, as the through holes h are accurately
aligned with the pixel electrodes 210, the portion of the transfer
layer 340 irradiated with the light is transformed only to the
pixel electrode 210.
[0041] As discussed previously, even though the donor mask 300 is
illustrated as spaced apart from the backplane, this is only for
convenience of description, and the donor mask 300 and the
backplane may be closely attached to each other. The close
attachment between the donor mask 300 and the backplane increases
transfer accuracy of a portion of the transfer layer 340 to the
backplane. When a distance between the donor mask 300 and the
backplane is large, even though only a portion of the transfer
layer 340 on the donor mask 300, which corresponds to the
transmission areas TA, is evaporated, vaporized, or sublimed, the
evaporated, vaporized, or sublimed material may move not only onto
the pixel electrodes 210 of corresponding sub-pixels but also onto
pixel electrodes 210 of neighboring sub-pixels.
[0042] After forming the red emission layers 220R as described
above, green emission layers or blue emission layers may be formed
on the pixel electrode 210 of green sub-pixels G or blue sub-pixels
B by exchanging the donor mask 300. In addition, according to
embodiments, an organic light-emitting display apparatus may be
manufactured by forming an electron injection layer, an electron
transport layer, and the like, followed by forming opposite
electrodes corresponding to the red sub-pixels R, the green
sub-pixels G, and the blue sub-pixels B.
[0043] In the method of manufacturing an organic light-emitting
display apparatus, when the portion of the transfer layer 340 on
the donor mask 300, which corresponds to the transmission areas TA,
is evaporated, vaporized, or sublimed, and then transferred to the
pixel electrodes 210 on the backplane, a layer of a preset
thickness is accurately formed to have uniform quality on the pixel
electrodes 210. That is, the transfer layer 340 on the donor mask
300 may have a uniform thickness, so a thickness of the transferred
portion (to be formed on the pixel electrode 210) is uniform.
[0044] To this end, before the portion of the transfer layer 340 on
the donor mask 300, which corresponds to the transmission areas TA,
is evaporated, vaporized, or sublimed, at least a portion of the
donor mask 300 or the transfer layer 340 is preheated. That is, the
layer having the preset thickness is accurately formed on the pixel
electrodes 210 with uniform quality by preheating at least a
portion of the donor mask 300 or the transfer layer 340, before
transforming a portion of the transfer layer 340 by irradiating a
laser beam or a lamp light on the preheated portion of the donor
mask 300 or the transfer layer 340. The reason for this is that the
transfer layer 340 corresponding to the preheated portion is
accurately evaporated, vaporized, or sublimed when the laser beam
or the lamp light is irradiated in a state where the donor mask 300
or the transfer layer 340 is preheated. If the laser beam or the
lamp light is irradiated in a state where the donor mask 300 or the
transfer layer 340 is not preheated, not all of the portion of the
transfer layer 340, which corresponds to the transmission areas TA,
is evaporated, vaporized, or sublimed, and a portion thereof
remains on the donor mask 300, thereby resulting in an abnormality
of the layer of the preset thickness.
[0045] The preheating of at least a portion of the donor mask 300
or the transfer layer 340 may be performed by various methods. For
example, as shown in FIG. 5 which is a side view for describing a
manufacturing process in the method of manufacturing the organic
light-emitting display apparatus according to an exemplary
embodiment, at least a portion of the donor mask 300 may be
preheated by irradiating a preliminary laser beam 410L thereon.
Once a portion of the donor mask 300 is preheated, a laser beam
420L may be irradiated on the preheated portion of the donor mask
300 to transfer a corresponding portion of the transfer layer 340.
In this case, as shown in FIG. 5, the preliminary laser beam 410L
may be emitted by a preliminary laser beam source 410, and the
laser beam 420L may be irradiated by a laser beam source 420. For
convenience, FIG. 5 illustrates only the substrate 100.
[0046] The preliminary laser beam 410L and the laser beam 420L may
have a size corresponding to the substrate 100 of the backplane or
may have a size that is less than that of the substrate 100 of the
backplane. For example, in FIG. 5, each of the preliminary laser
beam 410L and the laser beam 420L may have a long shape having a
long axis corresponding to a y axis (an axis directed into the
page). In this case, when the substrate 100 and the donor mask 300
move in a (+x) direction, while the preliminary laser beam 410L and
the laser beam 420L are irradiated, the laser beam 420L may be
naturally irradiated, e.g., immediately, onto a portion of the
donor mask 300 on which the preliminary laser beam 410L has already
been irradiated. In other words, the preliminary laser beam 410L
and the laser beam 420L may be sequentially irradiated onto a same
predetermined area of the donor mask 300, with the laser beam
source 420 irradiating an area previously irradiated, i.e.,
preheated, by the preliminary laser beam source 410.
[0047] In another example, the preliminary laser beam source 410
and the laser beam source 420 move in a (-x) direction, while the
substrate 100 and the donor mask 300 are fixed. In this case, the
laser beam 420L may be naturally irradiated on a portion of the
donor mask 300 on which the preliminary laser beam 410L has already
been irradiated, since the preliminary laser beam source 410 is
located at a portion of the (-x) direction relative to the laser
beam source 420. In other words, the preliminary laser beam 410L
and the laser beam 420L may be sequentially irradiated onto a same
predetermined area of the donor mask 300, with the laser beam
source 420 irradiating an area previously irradiated, i.e.,
preheated, by the preliminary laser beam source 410.
[0048] In yet another example, as shown in FIG. 6 which is a side
view for describing a manufacturing process in the method of
manufacturing the organic light-emitting display apparatus
according to another exemplary embodiment, the preliminary laser
beam 410L and the laser beam 420L may be emitted by a single laser
beam source 400. In this case, the preliminary laser beam 410L and
the laser beam 420L may be diverged by an optical element 430,
e.g., including a beam splitter, a reflective mirror, and the like,
from an original laser beam 400L emitted by the laser beam source
400. It is noted that only the laser beam source 400 without the
optical element 430 may be used. That is, the laser beam source 400
may first emit the preliminary laser beam 410L, and subsequently,
emit the laser beam 420L after a predetermined time period.
[0049] When the donor mask 300 or the transfer layer 340 is
preheated through the preliminary laser beam 410L by the various
methods described above, and thereafter a preset portion of the
transfer layer 340 is evaporated, vaporized, or sublimed by
irradiating the laser beam 420L to deposit a layer of a preset
thickness on the pixel electrodes 210 of the backplane, the
intensity of the preliminary laser beam 410L may be weaker than the
intensity of the laser beam 420L in order not to evaporate,
vaporize, or sublime the transfer layer 340 when the preliminary
laser beam 410L is irradiated and to evaporate, vaporize, or
sublime the transfer layer 340 when the laser beam 420L is
irradiated. In other words, the intensity of the preliminary laser
beam 410L is weaker than the that of the laser beam 420L to ensure
that the preliminary laser beam 410L only preheats a predetermined
area (rather than transforming it), while the intensity of the
laser beam 420L is sufficiently high to transfer a portion of the
transfer layer 340.
[0050] Although it has been described that a layer is deposited on
the pixel electrodes 210 of the backplane by irradiating a laser
beam to evaporate, vaporize, or sublime the transfer layer 340 on
the donor mask 300, the exemplary embodiments described above are
not limited thereto. For example, at least a portion of the donor
mask 300 may be preheated by irradiating a preliminary lamp light
(rather than a laser) thereon, and a lamp light may also be
irradiated to the preheated portion to facilitate transfer
thereof.
[0051] In this case, similarly to the embodiment illustrated in
FIG. 5, the preliminary lamp light may be emitted by a preliminary
lamp, and the lamp light may be emitted by a separate lamp that is
different from the preliminary lamp. Alternatively, similarly to
the embodiment illustrated in FIG. 6, the preliminary lamp light
and the lamp light may be emitted by one lamp, and in this case,
the one lamp may emit the preliminary lamp light and then emit the
lamp light with a time difference therebetween.
[0052] When the donor mask 300 or the transfer layer 340 is
preheated through the preliminary lamp light by the various methods
described above, and thereafter a preset portion of the transfer
layer 340 is evaporated, vaporized, or sublimed by irradiating the
lamp light to deposit a layer of a preset thickness on the pixel
electrodes 210 of the backplane, the intensity of the preliminary
lamp light may be weaker than the intensity of the lamp light. This
is not to evaporate, vaporize, or sublime the transfer layer 340
when the preliminary lamp light is irradiated and to evaporate,
vaporize, or sublime the transfer layer 340 when the lamp light is
irradiated. That is, the intensity of the preliminary lamp light is
weaker than the intensity of the lamp light capable of evaporating,
vaporizing, or subliming the transfer layer 340.
[0053] By way of summation and review, in an organic light emitting
diode of an organic light emitting diode display, a portion of each
of the layers included in the emission layer (that may correspond
to each sub-pixel) has to be formed by a separate process. However,
there is a high probability that the emission layer may not be
uniformly formed when such multiple forming processes are
performed. In contrast, according to exemplary embodiments, a
method of manufacturing a high-quality organic light-emitting
display apparatus may be implemented.
[0054] Example embodiments have been disclosed herein, and although
specific terms are employed, they are used and are to be
interpreted in a generic and descriptive sense only and not for
purpose of limitation. Accordingly, it will be understood by those
of skill in the art that various changes in form and details may be
made without departing from the spirit and scope of the present
invention as set forth in the following claims.
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